Method of and apparatus for manufacturing tuft yarn frames



March 29, 1932.

c. ALVORD METHOD OF AND APPARATUS FOR MANUFACTURING TUFT YARN FRAMESFiled Aug. 11. 1950 2 Sheets-Sheet Sm/E. 02380 INV ENTOR CgnTon Ah/ord MI! ATTORNEYS 55 530528 wg fimzmr u c. ALVORD 1,351,798

METHOD OF AND APPARATUS FOR MANUFACTURING TUFT YARN FRAMES March 29,1932.

Filed Aug. 11. 19:50

2 Sheets-Sheet 2 R .mA 5 N O E W MD MA O ple form of apparatusemployed-incarrying.

Patented Mar. 29,1932

UNITED; STATES NT OFFICE CLINTON ALVORD, OF WORCESTER,.MASSACHUSETTS,ASSIGNOR TO.WORCESTER"LOOMI WORKS, OF WORCESTER, MASSACHUSETTS, ACORPORATION OF MASSACHUSETTS METHOD OF AND APPARATUS FOR MANUFACTURINGTUFT YARN FRAMES Application filed August 11, 1930. Serial No. 474,332.

The object of the invention is to provide a method and apparatus bywhich the yarn guides in tuft frames of all widthsmay be I spaced withabsolute accuracy and permanently secured as thus spaced in position on.

the frame.

A further object of the inventionis to provide a method and apparatusfor producing such tuft yarn frames rapidly and economically andat aminimumcost.

A. further object ofrtheinvention is to provide a method and apparatusfor producing,

tuft yarn frames of that type in whichthe yarn guides are provided withjoints and in which the oints are permanently secured to gether so as toprevent the opening or spreading apart of the joints when the frames arethreaded and in use.

These and other, ob ects and features of the invention will appear morefully'from the accompanying;description and drawings and will beparticularly pointed out in the claims.

As the general purpose and function'ofa/ tuft yarn frame for use in aloom for weaving tufted pile carpet-s is well known and familiar tothose skilled in the art, and as various types of construction areadapted-to be made by the method and apparatus ofthis invention, it willbe sufficient here to illustrate and describe two types of such tuftyarn frames as typical. In the one type the yarn' guides are formed asseparate elements with overlapping joints and these elements areindividually secured to the carrier bar of the frame, whilein the othertype the yarn guides are formed in a unitary series in a crimped stripof metal which as an entirety is secured to the carrier bar of theframe.

In the drawings: Fig. 1 1S a diagrammaticelevation of asunout the methodofthe invention:

F ig. 2 is a view in end elevation of one of the two-part separableholders with a tuft yarn frame of the first type in place therein.

F ig. 3 is a view similar to Fig. 2 of another form of two-partseparable holder with'a tuft yarn frame of thesecond type in placetherein.

Fig. l is a front elevation partially broken, away showing a pluralityof the two-part separable holders with a completetuft' yarn frame of thefirst type in place therein.

Fig. 5 is a fragmentary perspective view of a spacer such as employed inthe construction shown in Figs. 2 and-4.

Fig. 6 is an enlarged end elevation of asingle yarn guide havingoverlapping-joints of the type shown in Figs. 2 and 4.

Fig; 7 is a perspective View ofaportion of the yarn guide structure ofthe second type.-

Fig. 8 is a fragmentary perspective view of a spacer such as employed inthe construction shown in Fig. 3. v

VVhichever'type of tuft yarn frame isemployed,.it is essential that thespacing of the yarn guides shall be regular, exact and equal throughoutthe length of the frame. Should this spacing vary even slightly, theyarn guiding elements would not properly penetrate between the warpyarns when the frame is dipped to insert the pile andthe result would bea defect in the fabric or'carpet being woven. These tuft yarn frames areoften twelve or more feet in length and there is a very substantialnumber of yarn guides; per inch depending upon the fineness of theweave. This invention enables such frames of any type and of any lengthto be formed with the yarn guides permanently and rigid ly secured inposition to the carrier baror main element of the frame and with all theyarn guides accurately and equally spaced. While soldering methods forsecuringjthe' yarn guides in place have long been used, it has beenpractically impossible to secureuni-' form and accurate results becauseor the dif-' ference in temperatures to which theyarn guides andthegauges employed wereraised and the unequal temperatures prevailing atthe timethe solder set-s."

Oneiimportant feature of thepresen-tin.-

vention resides in the employment of spacer means for positioning theyarn guides with respect to the carrier bar of the frame and in theraising of the entire ensemble to a uniform temperature suflicient tomelt the solder and then the gradual lowering of the temperature of thisentire ensemble to a point where the solder sets, thus ensuring that thespacing of the yarn guides is maintained throughout the entire operationand that there is no possibility of the'yarn guides being secured to thecarrier bar otherwise than in the required accurate and equal spacing.

Referring particularly to the construction illustrated in Figs. 2, l, 5,and 6, it will be seen that the yarn guide frame comprises a carrier bar1 shownas a rigid, rectangular tube of metal, thus presenting greatstrength and rigidity, and a series of yarn guide tubes 2. Each of theseyarn guides is of similar shape and is formed of sheet metal, usuallytin plated, having overlapping longitudinal back edges, as shown in Fig.6, where the back edge 3 overlaps the back edge 1. The ends of theseoverlapped back edges of the yarn guides overlie the carrier bar, asclearly shown in Fig. 2, and these overlapping edges are securedtogether and the yarn guides are secured to a carrier bar by solder sothat, when the operation is coinpletecha firm and rigid. unitarystructure is presented.

In order properly to space and position the yarn guides with respect tothe carrier bar, there is provided, in accordance with this in--vention, a temporary yarn guide spacer, a section of which is shown inperspective in Fig. 5. This spacer is shown as a block 5 of metal ofsuiiicient length to extend the length of the carrier bar and isprovided with a plurality of rows of rigid spaced projections 6 and isso shaped that, when the yarn guides are inserted in thespaces betweenthese pro jections, they will be properly spaced and assembled.Preferably also a plate 7 of metal extends along the front face of theblock 5 against which the front ends of the yarn guides abut and arethus positioned longitudinally. i

A plurality of two-part separable holders isprovided, the number ofthese holders depending upon thelength of the frame or carrier bar. Apreferred construction of such holder for use in forming a tubular yarnguide frame of the first type is shown in Figs.

1 andt. Each holder forms a two-part separable clamp. One part8 oftheholderorclamp presents a flat base 9 and a flat seat 10 upon whichthe temporary spacer 5 and theplate 7 are seated. The spacer 5 is alsosecured to the holder or clamp part 8 byset screws 11, as

shown. 1 7

hen all the parts-8 of the holders or clamps are secured inposition tothe spacer and the plate 7 is in place. the tubular yarn guides 2 arepositioned in'the spaces between the projections 6 with the forward endsabutting the plate 7 A long retaining bar 12 is then placed on top ofthe entire series of tubular yarn guides and clamped down against theyarn guides by set screws 13, one such set screw being verticallythreaded in a lug 14 projectinglaterally from each holder part 8.

The second part of each holder is somewhat 'U-shaped, as shown at 15,and of a size sufficient to receive the carrier bar 1. One leg of thispart of the holder or clamp fits in a suitable recess 16 of the lowerholder part and is provided with a notch 17 engaged by a spring-pressedplunger 18 mounted in the lower holder part. The other leg is alsoprovided with a notch 19 engaged by a similar spring-pressed plunger 20.A plunger 21 mounted vertically in the upper holder part is depressed bya spring 22 into engagement with the carrier bar.

The parts to be soldered are treated with a suitable flux. This isparticularly important in the case of that portion of the overlappedback edges of the yarn guides projecting laterally from the carrier barbecause the flux causes the solder applied at the end portions of theyarn guide to run substantially the full length of the yarn guides andinsures the soldering together of substantially the entire length of thejoint formed by the overlapped back edges. The flux may be convenientlyapplied to the tubular yarn guides 2 after the temporary spacer 5, theplate 7, and the yarn guides have been assembled in the lower holderpart.

A sheet or strip of solder such as 23 is next laid on the ends oftheback overlapping edges of the tubular yarn guides. The carrier bar 1 isthen placed in theupper holder part 15 and this holder part is thenplaced in position on the lower holder part and the plungers 18 and .20snap into position and lock the holder parts or clamps together. In thisposition the spring-pressed plunger-s 21 act yieldingly to press the rowof positioned yarn guides and the carrier bar together with the strip orlayer of solder 28 interposed between the ends of the overlapped bacl:edges of the yarn guides and the front surface of the carrier bar. Thelefthand holder 5 is provided at one end with an upturned stop 24. toposition the carrier bar longitudinally with respect to the tubular yarnguides. An abutting post 25 on each lower holder extending up to a pointslightly below the level of the top of the positioned yarn guidesprevents the carrier bar from tipping while the parts are beingassembled. hen the assembly is completed, the spring-pressed plungers 21hold the carrier ,bar in proper position clear of these post-s 25. Theholder or clamp parts are readily assembled by forcing the upper partdown upon the lower part, causing the spring-pressed-plungers 18 and 20.which are bevelled at their free ends, to spring into 1 flat uppersurfaces.

ram-.798.

the notches 17 and 19, and thetwo holder or clamp parts are quicklydetachable by pressing the plungers 18 and 19 inward by means of thehandles 26'. I

The ensemble comprising a plurality of, the two-part holders or clamps,the temporary spacer 5, the plate 7, the series of tubular yarn guides 2mounted in the spacer,'the strip of solder 23, and the carrier bar 1-all locked together is shown in Fig. 4..

This ensemble, in accordance with the method of, this invention, is nowas a whole raised in temperature to a point sufficient to melt thesolder. Thus the entire ensemble maintains the same temperature andconsequently there is no relative shifting or distortion of the parts. IAs the solder melts, the spring-pressed plungers 21 force the carrierbar and the positioned yarn guides together,

' thus causing not only the yarn guides and the carrier bar but theoverlapped back edges of the yarn guides all throughly to be soldered orsweated together. The temperature of the entire ensemble isthengradually reduced to room temperature or to the point where thesolder is set, the yielding pressure of the plungers 25 being maintainedthroughout. The operation is now complete and the clamps or holders areremoved, together with the temporary spacer. The result is a tuft yarnframe in which all the tubular yarn guides are accurately and equallyspaced and permanently and thoroughly secured in position to the carrierbar, and the overlapped Shack edges of the yarn guides, are solderedtogether substantially for their full length.

A preferred form of apparatus for raising: and lowering the temperatureof the ensemble is shown somewhat digrammatically in It comprises anoven 27 of sufiicient length and size to contain the entire ensemble.This oven may be heated by gas or other suitable means and is preferablyprovided with thermostatic means "for maintaining it ata constanttemperature of, say, about 445 FJ Doors 28 and 29 are provided at theends of the oven. An assembly table30-is located at oneend of the ovenand a cooling table 31 at the other end. These tables present rigid,

ably put together on the assembly table 30.. "When completed, the door128 is, opened and the ensemble is pushed into the, oven; It thenremains in the oven a sufficient length of time,

say about thirty minutes, to enable all the parts of the ensemble toreach a uniform tem perature above the melting point of the solder. Thedoor 29 of the oven is then opened and the ensemble drawn out upon thecooling table 31 and left until the ensemble reaches room temperatureand the solder sets. The rigid fiat surface of the cooling table 31insures that the tube frames shall not become warped while cooling. Whenthe ensembleis removed from the; oven, the. operative makes The ensembleis prefer-1 Fig. 7 in perspective a portion of tuft frame such asdisclosed inthe patent to Alvord, No. 1,713,506,,granted May 14, 1929.The only. difference in this case is that the twoart separable holder orclamp is of a sligltly different design to accommodate this type of tuftframe. One of the holders or clamps for this purpose is shown in Fig. 3.In this case the carrier bar 32 is seated in the lower holder part 33which is of general U shape.- The strip 34 forming the series of yarnguides is placed inposition overlying the carrier bar with the strip 35of solder interposed. The: temporary spacer 36 is shaped as shown inFig. 8 with the projections 37 adapted to fit in the spaces forming theyarn guides of the strip 34. This spacer is placed in position with asuitable end positioning plate 38. The upper holder part 39 is-thenplaced in position and is provided with spring-pressed plungers40similar to those already described by which the two parts of theholder are detachably connected together. The spring pressed plunger 41in the upper holder member abuts the temporary spacer 36 and thus actsyieldingly to press the yarn guide strip and carrier bar with theinterposed strip of solder together. A positioning lug 42 onthe end ofthe,temporaryspacer 36 has the same function as the lug 24 alreadydescribed.

After the parts have been assembled, the entire ensemble is then treatedin the same manner as already described. The result is that. the yarnguide strip 34 is permanently and rigidly secured to the carrier barwith thespaces forming the yarn guides all accurately and equallypositioned.

There is thus presented a simple form of apparatus and method by meansof which tuft yarn frames may be easily and economically manufacturedand in which the yarn guides will be accurately andequally spacedthroughout and rigidly andpermanently secured in position.

Having thus described the invention, what is claimed as new, and desiredto be secured by Letters Patent, is:

1. The process of forming a tuft yarn frame which comprises assembling acarrier bar, a plurality of yarn guides, and a temporary yarn guidespacer with the spacer accurately and uniformly positioning the yarnguides, with the ends of the backs of the pothereafter gradually coolingthe ensemble to room temperature, maintaining a yielding pressure actingto force the yarn guides and carrier bar together while the temperatureof the ensemble is being raised and while it is being lowered to a pointwhere the solder is set, and removing the temporary spacer.

2. The process of forming a tuft yarn frame comprising the steps definedin claim 1, together with supporting the ensemble during the coolingstep straight upon a rigid support.

3. The process of forming a tuft yarn frame which comprises assembling acarrier a bar, a plurality of yarn guides, and a temporary yarn guidespacer with the spacer accurately and uniformly positioning the yarnguides, with the ends of the backs of the positioned yarn guidesoverlying the carrier bar, and with a layer of solder interposed betweenthe said yarn guides and the carrier bar, placing the ensemble in anoven maintained at a temperature above the melting point of the solder,leaving the ensemble in s the oven until it has reached the saidtemperature, thereafter gradually cooling the ensemble to roomtemperature, maintaining a yielding pressure acting to force the yarn Nguides and carrier bar together while the temperature of the ensemble isbeingraised and While it is being lowered to a point where the solder isset, and removing the temporary spacer.

4. The process of forming a tuft yarn frame comprising the steps definedin claim frame which comprises assembling a carrier bar, a pluralityoftubular yarn guides each having overlapping longitudinal back edges,

and av temporary yarn guide spacer with the spacer accurately anduniformly positioning the yarn guides, with the ends ofthe overlappedback edges of the positioned 'yarn guides overlying the carrier bar, andwith a layer of sold-er interposed betweenthe yarn v guides and thecarrier bar, raising the tem-- perature of the ensemble to a pointsufficient to 'melt the solder, thereafter gradually cool ing theensemble to room temperature, maintainlng a yielding pressure acting toforce the overlapping back edges of the yarn guides ---together andthe'yarn guides and carrier bar together while the temperature of theensemble is being raised and while it is being lowered to a point wherethe solder is set,

thus to effect a permanent union both between the overlapped edges ofthe yarn guides and between the yarn guides and the j carrier bar andremoving the temporary spacer. I I

6. The process of forming a tuft yarn frame comprising the steps definedin claim lapped back edges of the yarn guides whereo by the solderinterposed between the ends of the yarn guides and the carrier bar flowsthroughout substantially the length of the yarn guides and efiects apermanent union between the overlapped edges of the yarn guidessubstantially throughout their length.

8. The process of forming a tuft yarn frame which comprises assembling acarrier bar, a plurality of tubular yarn guides each having overlappinglongitudinal back edges, and a temporary yarn guide spacer with thespacer accurately and uniformly positioning the yarn guides, withtheends of the overlapped back edges of the positioned yarn guidesoverlying the carrier bar, and with a layer of solder interposed betweenthe said yarn guides and the carrier bar, placing the ensemble in anoven maintained at a term perature above the melting point of the s-older, leaving the ensemble in the oven until it has reached the saidtemperature, there after gradually cooling the ensemble to roomtemperature, maintaining a. yielding pressure acting to force theoverlapping back edges of the yarn guides together and the yarn guidesand carrier bar together while the temperature of the ensemble is beingraised and while it is being lowered to a point where the solder is set,thus to eflect a permanent union both between the overlapped edges ofthe yarn guides and between the yarn guides. and the carrier bar andremoving the temporary spacer.

'9. The process of forming a tuft yarn frame comprising the stepsdefined in claim 8, together with supporting the ensemble during thecooling step straight upon a rigid support. 7

10. The process; of forming a tuft yarn frame comprising the stepsdefined in claim 8, together with applying a flux to the overlapped backedges of the yarn guides whereby the solder interposed between the endsof the yarn guides and the carrier bar flows throughout substantiallythe length of the yarn guides and effects a permanent union between theoverlapped edges of the yarn guides substantially throughout theirlength.

11. An apparatus for forming a tuft yarn frame comprising a two-partseparable holder, a yarn guide spacer mounted in oneholder part toposition accurately and uniformly tuft frame yarn guides in parallelismand in straight alignment, means in the other holder partto supportremovably a carrier bar with its front surface in juxtaposition to theends of the backs of the positioned yarn guides and means on one holderpart acting yieldingly to press the row of positioned yarn guides andcarrier bar together when the holder parts are assembled.

12. An apparatus for forming a tuft yarn frame comprising theconstruction defined in claim 11, together with cooperating lookingmeans on the holder parts for locking them together in assembledposition.

13. An apparatus for forming a tuft yarn frame comprising theconstruction defined in claim 11, together with cooperating,spring-actuated, locking means on the holder parts for locking themtogether in assembled position.

14. An apparatus for forming a tuft yarn frame comprising a series ofsimilar two-part, separable, transversely spaced clamps, a long rigidspacer extending transversely of and mounted in one part of each clampto position accurately and uniformly tuft frame yarn guides inparallelism and in straight align ment, aligned means in the other partof each clamp to support removably a carrier bar with its front surfacein juxtaposition to the ends of the backs of the positioned yarn guides,and means on each clamp acting yieldingly to press the row of positionedyarn guides and carrier bar together when the apparatus is assembledwith the yarn guides and carrier bar therein.

In testimony whereof, I have signed my name to this specification.

CLINTON ALVORD.

